Apparatus, System, and Method for Performing an Electrosurgical Procedure

ABSTRACT

A bipolar forceps includes a shaft extending from a housing and includes an end effector assembly at its distal end. The end effector assembly has a pair of jaw members movable between an open position and a closed position. A knife assembly includes a cutter having a generally circular cross-section. The cutter is configured to cut tissue when the jaw members are in the closed position. One or more electrically conductive tissue sealing plates are disposed on each of the jaw members. The tissue sealing plates are adapted to connect to an electrosurgical energy source configured to deliver electrosurgical energy to tissue held between the jaw members to effect a tissue seal. An actuator is operably coupled to the knife assembly and is configured to selectively reciprocate the cutter relative to the jaw members.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 12/574,001, filed on Oct. 6, 2009, the entire contents of which are incorporated herein by reference.

BACKGROUND

1. Technical Field

The present disclosure relates to an apparatus, system, and method for performing an electrosurgical procedure. More particularly, the present disclosure relates to an apparatus, system, and method for performing an electrosurgical procedure that employs an electrosurgical apparatus that includes an end effector assembly configured for use with various size access ports.

2. Description of Related Art

Electrosurgical apparatuses (e.g., electrosurgical forceps) are well known in the medical arts and typically include a handle, a shaft and an end effector assembly operatively coupled to a distal end of the shaft that is configured to manipulate tissue (e.g., grasp and seal tissue). Electrosurgical forceps utilize both mechanical clamping action and electrical energy to effect hemostasis by heating the tissue and blood vessels to coagulate, cauterize, seal, cut, desiccate, and/or fulgurate tissue

As an alternative to open electrosurgical forceps for use with open surgical procedures, many modern surgeons use endoscopes and endoscopic electrosurgical apparatus (e.g., endoscopic forceps) or laparoscopic forceps for remotely accessing organs through smaller, puncture-like incisions. As a direct result thereof, patients tend to benefit from less scarring and reduced healing time. Typically, the forceps are inserted into the patient through one or more various types of cannulas or access ports (typically having an opening that ranges from about five millimeters to about twelve millimeters) that has been made with a trocar; as can be appreciated, smaller cannulas are usually preferred.

Forceps that are configured for use with small cannulas (e.g., cannulas less than five millimeters) may present design challenges for a manufacturer of electrosurgical instruments.

SUMMARY

According to an embodiment of the present disclosure, a bipolar forceps includes a shaft extending from a housing and includes an end effector assembly at its distal end. The end effector assembly has a pair of jaw members movable between an open position and a closed position. A knife assembly includes a cutter having a generally circular cross-section. The cutter is configured to cut tissue along the tissue seal when the jaw members are in the closed position. One or more electrically conductive tissue sealing plates are disposed on each of the jaw members. The tissue sealing plates are adapted to connect to an electrosurgical energy source configured to deliver electrosurgical energy to tissue held between the jaw members to effect a tissue seal. An actuator is operably coupled to the knife assembly and is configured to selectively reciprocate the cutter relative to the jaw members to divide tissue.

According to another embodiment of the present disclosure, a bipolar forceps includes a shaft extending from a housing and including an end effector assembly at its distal end. The end effector assembly has a pair of jaw members movable between an open position wherein the jaw members are disposed in spaced relation relative to each other and a closed position wherein the jaw members cooperate to grasp tissue. The forceps also includes a knife assembly including a cutter having a generally circular cross-section. The cutter is configured to cut the tissue when the jaw members are in the closed position. The forceps also includes one or more electrically conductive tissue sealing plates disposed on each of the jaw members. The electrically conductive tissue sealing plates are adapted to connect to an electrosurgical energy source and are configured to deliver electrosurgical energy to tissue held between the jaw members to effect a tissue seal. The forceps also includes a knife channel disposed through at least one of the jaw members. The cutter is configured to reciprocate within the knife channel when the jaw members are in the closed position to divide tissue grasped between the jaw members. An actuator is operably coupled to the knife assembly and is configured to selectively reciprocate the cutter through the knife channel.

According to another embodiment of the present disclosure, a method for performing an electrosurgical procedure includes the step of providing an electrosurgical apparatus. The electrosurgical apparatus includes a shaft extending from a housing. The shaft includes an end effector assembly at its distal end. The end effector assembly has a pair of jaw members movable between an open position and a closed position. The electrosurgical apparatus also includes a knife assembly. The knife assembly includes a cutter having a generally circular cross-section. The cutter is configured to cut tissue along the tissue seal when the jaw members are in the closed position. One or more electrically conductive tissue sealing plates are disposed on each of the jaw members. The tissue sealing plates are adapted to connect to an electrosurgical energy source configured to deliver electrosurgical energy to tissue held between the jaw members to effect a tissue seal. The electrosurgical apparatus also includes an actuator operably coupled to the knife assembly. The actuator is configured to selectively reciprocate the cutter relative to the jaw members to divide tissue. The method also includes the step of delivering electrosurgical energy from the electrosurgical energy source to the electrically conductive tissue sealing plates to achieve a desired tissue effect. The method also includes the step of actuating the cutter to selectively separate the effected tissue from the rest of the effected tissue.

According to another embodiment of the present disclosure, a method of manufacturing a jaw member of an electrosurgical apparatus includes the steps of drilling a channel through the longitudinal thickness of a substantially cylindrical workpiece and making a longitudinal cut through a portion of the workpiece to substantially bisect the channel along at least a portion of the length thereof. The method also includes the step of making a cross-sectional cut through a portion of the workpiece to intersect the longitudinal cut to facilitate removal of a section defined by the intersecting cuts from the workpiece.

BRIEF DESCRIPTION OF THE DRAWING

Various embodiments of the present disclosure are described hereinbelow with references to the drawings, wherein:

FIG. 1 is a right perspective view of an endoscopic bipolar forceps showing a housing, a shaft, and an end effector assembly in accordance with the present disclosure;

FIG. 2 is an enlarged, right perspective view of the end effector assembly of FIG. 1;

FIGS. 3A and 3C are enlarged, side views of the end effector assembly of FIG. 1;

FIGS. 3B and 3D are cross-sectional views taken along section lines 3B-3B and 3D-3D of FIGS. 3A and 3C, respectively;

FIG. 4A is a side view of a cutter according to an embodiment of the present disclosure;

FIG. 4B is a side view of a cutter according to another embodiment of the present disclosure;

FIG. 5A is an enlarged, side view of the end effector assembly of FIG. 1 according to an embodiment of the present disclosure;

FIG. 5B is a cross-sectional view taken along section line 5B-5B of FIG. 5A;

FIG. 5C is an enlarged, side view of the end effector assembly of FIG. 1 according to another embodiment of the present disclosure;

FIG. 5D is an enlarged, side view of the end effector assembly of FIG. 1 according to another embodiment of the present disclosure;

FIG. 6A is side view of a workpiece according to an embodiment of the present disclosure;

FIG. 6B is a cross-sectional view taken along section line 6B-6B of FIG. 6A;

FIGS. 6C and 6D are side views of the workpiece of FIG. 6A;

FIG. 6E is a side view of the workpiece of FIG. 6A with a section removed; and

FIG. 6F is a cross-sectional view taken along section line 6E-6E of FIG. 6D.

DETAILED DESCRIPTION

Embodiments of the presently disclosed apparatus are described in detail below with reference to the drawings wherein like reference numerals identify similar or identical elements in each of the several views. In the discussion that follows, the term “proximal” or “trailing” will refer to the portion of a structure that is closer to a user, while the term “distal” or “leading” will refer to the portion of the structure that is farther from the user.

As noted above, it may prove useful in the arts to provide an electrosurgical apparatus that is suitable for use with various access ports, including but not limited to those that are greater than and/or less than five millimeters. With this purpose in mind, the present disclosure includes an electrosurgical forceps that includes a drive assembly operatively coupled to one or more jaw members associated with the end effector assembly of the electrosurgical forceps. The drive assembly is configured to move the jaws from an open to a closed configuration that forms a closed loop electrical circuit such that a desired tissue effect (e.g., a tissue seal) may be achieved.

The electrosurgical forceps includes a knife assembly incorporating a cutter having a generally circular cross-section. The cutter may be, for example, wire, tubing, rod, hypodermic tubing, hypodermic needle, or the like. The cutter is operably coupled at a proximal end to the drive assembly and/or an actuator and includes a distal end having any one of various geometries and/or dimensions configured to divide tissue, as discussed in further detail below.

Turning now to FIG. 1, an embodiment of an endoscopic bipolar forceps 10 is shown for use with various surgical procedures and generally includes a housing 20, a handle assembly 30, a rotating assembly 80, a trigger assembly 70, and an end effector assembly 100 that mutually cooperate to grasp, seal, and divide tubular vessels and vascular tissue. Although the majority of the figure drawings depict a bipolar forceps 10 for use in connection with endoscopic surgical procedures, the present disclosure may be used for more traditional open surgical procedures. Forceps 10 includes a shaft 12 that has a distal end 14 dimensioned to mechanically engage the end effector assembly 100 and a proximal end 16 that mechanically engages the housing 20. For the purposes herein, the forceps 10 is described in terms of a laparoscopic instrument, however, it is contemplated that an open version of the forceps may also include the same or similar operating components and features as described below.

Forceps 10 includes an electrosurgical cable 310 that connects the forceps 10 to a source of electrosurgical energy, e.g., a generator (not shown). One such source of electrosurgical energy is described in commonly-owned U.S. Pat. No. 6,033,399 entitled “ELECTROSURGICAL GENERATOR WITH ADAPTIVE POWER CONTROL”. Cable 310 is internally divided into cable leads 310 a, 310 b, and 310 c, that are designed to transmit electrical potentials through their respective feed paths through the forceps 10 to the end effector assembly 100.

For a more detailed description of handle assembly 30, movable handle 40, rotating assembly 80, and electrosurgical cable 310 (including line-feed configurations and/or connections) reference is made to commonly owned Patent Publication No., 2003-0229344, filed on Feb. 20, 2003, entitled VESSEL SEALER AND DIVIDER AND METHOD OF MANUFACTURING THE SAME.

Handle assembly 30 includes a fixed handle 50 and a movable handle 40. Fixed handle 50 is integrally associated with housing 20 and handle 40 is movable relative to fixed handle 50 as explained in more detail below with respect to the operation of the forceps 10. Rotating assembly 80 is operatively connected to the housing 20 and is rotatable approximately 180 degrees in either direction about a longitudinal axis “A-A” (See FIG. 1).

As mentioned above, end effector assembly 100 is attached at the distal end 14 of shaft 12 and includes a pair of opposing jaw members 110 and 120. Movable handle 40 of handle assembly 30 is operatively connected to a drive assembly 150 (shown in phantom) that, together, mechanically cooperate to impart movement of the jaw members 110 and 120 from an open position wherein the jaw members 110 and 120 are disposed in spaced relation relative to one another, to a clamping or closed position wherein the jaw members 110 and 120 cooperate to grasp tissue therebetween. With this purpose in mind, drive assembly 150 may include any suitable number of electrical connections, configurations, and/or components (e.g., resistors, capacitors, inductors, rheostats, etc.), mechanical connections, configurations, and/or components (e.g., gears, links, springs, rods, etc.), and/or electro-mechanical connections, configurations, and/or components such that forceps 10 may function as intended.

As shown best in FIGS. 2 and 3A-3D, the end effector assembly 100 includes opposing jaw members 110 and 120 that cooperate to effectively grasp tissue for sealing purposes. The end effector assembly 100 may be designed as a unilateral assembly, i.e., jaw member 120 is fixed relative to the shaft 12 and jaw member 110 pivots about a pivot pin 103 relative to jaw member 120 to grasp tissue, or as a bilateral assembly, i.e., jaw members 110 and 120 pivot about pivot pin 103 relative to each other to grasp tissue. In some embodiments, jaw members 110, 120 are operably coupled to each other about a pivot pin 103 that allows jaw member 110 to pivot relative to stationary jaw member 120.

In some embodiments, the pivoting jaw member 110 is actuated by the drive assembly 150 such that distal movement of drive assembly 150 pivots jaw member 110 relative to jaw member 120 to an open position wherein the jaw members 110, 120 are in spaced relation relative to each other and proximal movement of drive assembly 150 pivots jaw member 110 relative to jaw member 120 to a closed position to grasp tissue therebetween. In another embodiment, pivot pin 103 is configured to slide within a cam slot (not shown) to pivot jaw member 110 between the open and closed positions.

As best shown in FIG. 2, jaw member 110 also includes a jaw housing 116 that has an insulative substrate or insulator 114 and an electrically conducive surface 112. Insulator 114 is configured to securely engage the electrically conductive sealing surface 112. This may be accomplished by stamping, by overmolding, by overmolding a stamped electrically conductive sealing plate and/or by overmolding a metal injection molded seal plate.

All of these manufacturing techniques produce jaw member 110 having an electrically conductive surface 112 which is substantially surrounded by an insulating substrate 114. The insulator 114, electrically conductive sealing surface 112 and the outer, non-conductive jaw housing 116 are configured to limit and/or reduce many of the known undesirable effects related to tissue sealing, e.g., flashover, thermal spread and stray current dissipation. In other embodiments, the jaw members 110 and 120 may be manufactured from a ceramic-like material and the electrically conductive surface(s) 112 are coated onto the ceramic-like jaw members 110 and 120.

Jaw member 120 includes similar elements to jaw member 110 such as jaw housing 126 having an insulator 124 and an electrically conductive sealing surface 122 that is dimensioned to securely engage the insulator 124.

As best shown in FIGS. 2 and 3A-3D, a knife channel 115 is defined through the center of jaw member 120. As best shown in the cross-sections of FIGS. 3B and 3D, knife channel 115 may be substantially semi-circular in shape and configured to accommodate a cutter 132 therethrough. As best shown in FIGS. 3A-3D, cutter 132 includes a generally circular cross-section and is configured to advance along knife channel 115 such that at least a portion of the cross-section of cutter 132 is disposed outside of knife channel 115 between jaw members 110 and 120. Activation of cutter 132 is caused by an actuator such as, for example, trigger assembly 70 and/or handle assembly 30. When activated, the cutter 132 advances through knife channel 115 to progressively and selectively divide tissue along a tissue plane in a manner to effectively and reliably divide the tissue. In some embodiments, forceps 10 may be configured such that cutter 132 may only be advanced through knife channel 115 to cut tissue when jaw members 110, 120 are in the closed position to prevent accidental or premature activation of cutter 132 through tissue. In embodiments, tissue grasped between jaw members 110, 120 need not be sealed for cutter 132 to be utilized to divide such tissue. That is, it is not necessary to perform the step of cutting tissue subsequent to or prior to the step of sealing tissue. Likewise, nor is it necessary to perform the step of sealing tissue subsequent to or prior to the step of cutting tissue. For example, tissue may be sealed but not cut. Likewise, tissue may be cut and not sealed.

By way of example, cutter 132 may be a solid wire, a tube (e.g., hypodermic tubing), a rod, a hollow hypodermic needle, a flexible metal, spiral-cut wire, etc.

In the illustrated embodiment of FIGS. 3A and 3C, cutter 132 includes a substantially blunt tip 133. In other embodiments, cutter 132 may include various geometries and/or distal tips to facilitate reliable division of tissue. More specifically, FIG. 4A shows one embodiment of cutter 132 having an angled distal tip 135 that forms a chisel-type configuration. In yet another embodiment, FIG. 4B shows cutter 132 having a tapered distal end 136 that extends distally to a sharpened distal tip 137. Other distal tip geometries and/or configurations are contemplated and the above embodiments should not be construed as exhaustive.

In another embodiment shown in FIGS. 5A and 5B, jaw member 110 may also include a knife channel 215 that substantially aligns with knife channel 115 of jaw member 120 such that each of knife channels 115 and 215 receive at least a portion of the cross-section of cutter 132 upon advancement therethrough. In this manner, the generally circular cross-section of cutter 132 is accommodated within both knife channels 115 and 215 upon advancement therethrough to aid in aligning the jaw members 110, 120 during cutting of tissue grasped therebetween.

The generally circular cross-section of cutter 132 makes it possible for cutter 132 to advance or snake through various configurations of channels. With this purpose in mind, end effector 100 may include a helical knife channel 315, as shown in the embodiment of FIG. 5C. More specifically, knife channel 315 is spirally defined through both jaw members 110, 120 continuously, such that cutter 132 may be advanced through knife channel 315 in a helical-like manner to progressively and selectively divide tissue along a tissue plane. In this scenario, activation of cutter 132 (e.g., via trigger assembly 70 and/or handle assembly 30) may cause cutter 132 to be advanced distally while being simultaneously rotated about its longitudinal axis to aid in the helical-like advancement through knife channel 315.

In another embodiment shown in FIG. 5D, cutter 132 is configured to be advanced distally such that at least a portion thereof is disposed distal to a distal end of jaw members 110, 120. In this scenario, cutter 132 may be embodied as a hollow hypodermic needle operably coupled to a fluid source (not shown) such that fluid may be injected from cutter 132 into tissue. For example, cutter 132 may be used to inject a nerve block agent into a desired tissue location prior to and/or during a surgical procedure (e.g., a polypectomy) to reduce pain. In another scenario, cutter 132 may be embodied as a conductive wire or rod and operably coupled to the same source of electrosurgical energy as forceps 10 or an alternative source of electrosurgical energy. In this manner, cutter 132 may be configured to operate as a monopolar electrode and used to cauterize tissue, for example, as a follow up to tissue sealing and/or cutting. Further, cutter 132 may be selectively energizable by the surgeon during cutting. In this way, the surgeon may electrosurgically cut the tissue along the tissue seal. As a result, cutter 132 may be substantially dull and still be employed to electrosurgically cut tissue.

As best shown in FIG. 3A, jaw member 120 may include a series of stop members 750 disposed on the inner facing surfaces of the electrically conductive sealing surface 122 to facilitate gripping and manipulation of tissue and to define a gap “G” (FIG. 4) between opposing jaw members 110 and 120 during sealing and cutting of tissue. Pivoting jaw member 110 pivots about pivot pin 103 to the closed position such that conductive sealing surface 112 engages stop members 750. The series of stop members 750 may be employed on one or both jaw members 110 and 120 depending upon a particular purpose or to achieve a desired result. A detailed discussion of stop members 750 as well as various manufacturing and assembling processes for attaching and/or affixing the stop members 750 to the electrically conductive sealing surfaces 112, 122 are described in commonly owned, co-pending U.S. Patent Publication Application No. 20040122423 entitled “VESSEL SEALER AND DIVIDER WITH NON-CONDUCTIVE STOP MEMBERS” by Dycus et al.

FIGS. 6A-6F illustrate a method of manufacturing a jaw member including a knife channel For purposes of illustration, the method illustrated in FIGS. 6A-6F is discussed with reference to jaw member 120 and knife channel 115 as substantially described above with respect to the other embodiments. In FIGS. 6A and 6B, a substantially cylindrical machined steel workpiece 125 is shown. Utilizing a suitable drilling device and corresponding drill-bit, a knife channel 115 is drilled a predetermined distance through at least a portion of the longitudinal thickness of the workpiece 125. In some embodiments, knife channel 115 may be drilled at a predetermined position with respect to the diameter of the workpiece 125 (e.g., the center point). As shown in FIGS. 6C and 6D, the drilling of knife channel 115 may be initiated at either end of workpiece 125 and subsequently drilled toward the end opposing the end through which drilling was initiated. Once knife channel 115 is drilled into workpiece 125, a section 125′ of workpiece 125 is cut and removed from the workpiece 125′ to generate jaw member 120, as shown in FIGS. 6C-6F. More specifically, a longitudinal cut 127 a through a portion of workpiece 125 substantially bisects knife channel 115 along at least a portion of its length and intersects a cross- sectional cut 127 b through workpiece 125 such that section 125′ may then be separated from workpiece 125. As shown in the cross-section of FIG. 6E, knife channel 115 is substantially semi-circular in shape. In the illustrated embodiment, knife channel 115 is drilled into workpiece 125.

While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto. 

1. A bipolar forceps, comprising: a housing having a shaft that extends therefrom including an end effector assembly at a distal end thereof, the end effector assembly having a pair of jaw members movable between an open position wherein the jaw members are disposed in spaced relation relative to each other and a closed position wherein the jaw members cooperate to grasp tissue therebetween; a knife assembly including a cutter having a generally circular cross-section and configured to cut the tissue when the jaw members are in the closed position; at least one electrically conductive tissue sealing plate disposed on each of the jaw members, the electrically conductive tissue sealing plates adapted to connect to an electrosurgical energy source configured to deliver electrosurgical energy to tissue held between the jaw members to effect a tissue seal; and an actuator operably coupled to the knife assembly and configured to selectively reciprocate the cutter relative to the jaw members.
 2. A bipolar forceps according to claim 1, further comprising: a knife channel disposed through at least one of the jaw members, wherein the cutter is configured to reciprocate within the knife channel when the jaw members are in the closed position to divide tissue grasped therebetween.
 3. A bipolar forceps according to claim 2, wherein each jaw member includes a knife channel disposed therethrough configured to substantially align with each other such that the cutter is configured to reciprocate within the knife channels when the jaw members are in the closed position to divide the tissue grasped therebetween.
 4. A bipolar forceps according to claim 2, wherein the knife channel is spirally defined through the jaw members to define a substantially helical shape.
 5. A bipolar forceps according to claim 4, wherein the cutter is configured to snake through the knife channel upon advancement therethrough.
 6. A bipolar forceps according to claim 1, wherein a distal tip of the cutter is angled with respect to a longitudinal axis of the cutter.
 7. A bipolar forceps according to claim 1, wherein the cutter includes a tapered distal end extending to a sharpened tip.
 8. A bipolar forceps according to claim 1, wherein the cutter includes a blunt distal tip.
 9. A bipolar forceps according to claim 1, wherein the cutter is selected from the group consisting of a wire, a tube, a hypodermic needle, and a cable.
 10. A bipolar forceps according to claim 1, wherein the cutter is configured to substantially align the jaw members in the closed position upon advancement through the knife channel
 11. A bipolar forceps according to claim 1, wherein the actuator is in electromechanical cooperation with the source of electrosurgical energy, the actuator allowing a user to selectively supply electrosurgical energy to the cutter to electrosurgically divide the tissue.
 12. A bipolar forceps according to claim 1, further comprising a trigger disposed within the housing and in electromechanical cooperation with the source of electrosurgical energy, the trigger allowing a user to selectively supply bipolar energy to each of the jaw members to effect a tissue seal.
 13. A method of manufacturing a jaw member of an electrosurgical apparatus, comprising the steps of: drilling a channel through the longitudinal thickness of a substantially cylindrical workpiece; making a longitudinal cut through a portion of the workpiece to substantially bisect the channel along at least a portion of the length thereof; and making a cross-sectional cut through a portion of the workpiece to intersect the longitudinal cut to facilitate removal of a section defined by the intersecting cuts from the workpiece. 